Implement holder and method of making same

ABSTRACT

An implement holder having at least one integral pocket for receiving an implement or tool. The implement holder includes a deformable sheet and a backing. The backing is mounted to the sheet at least about its periphery to support the sheet and provide a back surface for the pocket. The implement holder is constructed by molding a cavity in the sheet of material to provide the pocket, providing an opening in the cavity so that the cavity has an open end, and securing the backing to the wall to complete the pocket.

United States Patent March 1 1 Apr. 29, 1975 15 1 IMPLEMENT HOLDER ANDMETHOD OF 2.350.152 9/1958 Marrufo 206/471 MAKING ME 533???? 3/1325li?"" "3552 62 3C0 t v [75] Inven or: Joseph E. March. Chicago. Ill.3.097.787 7/1963 Schur 229/53 3.121.492 2/l964 DcPaul ct al. 206/443[73] Ass'gnee" Luggage 3.139.182 6/1964 Edell 206/471 [22 Fil d; M 19,1973 3.404.774 10/1968 Levine 206/464 [711 A N 342 846 3.648.3l8 3/1972Tsuruzawa 206/38 R Related US. Application D t Primary Examiner-WilliamT. Dixson, Jr. [63] Continuution-in-pz1rt of Scr. No. 128.878. March 29.Attorney Agent or Even Tabm &

I971. abandoned. Luedeka [52] US. Cl. 206/373; 206/461; 224/5 A; [57]ABSTRACT 19 7 [51 Int Cl g g3 An implement holder having at least oneintegral [is] Fie'Id 464 469 pocket for receiving an implement or tool.The imple- 206/806 4XL T 38 224/5 5 f ment holder includes a deformablesheet and a back- .)9/l63 R. 5 55 R. 4 ing. The backing is mounted tothe sheet at least about its periphery to support the sheet and providea buck surface for the pocket. The implement holder is constructed bymolding a cavity in the sheet of material to [56] References cuedprovide the pocket. providing an opening in the cavity UNITED STATESPATENTS so that the cavity has an open end. and securing the 1.094.0094/1914 Parkhurst 206/373 backing to the wall to complete the pocket.2.377.166 5/1945 Muycr 224/5 A 2.816.666 12/1957 Nudcl 206/461 9 ChumsDrawing Figures R JENTEEAPMQQYS SHEET 10? 3 PHENTEB 3.880.285

SHEET 2 [1F 3 PIXTENTEU APR 2 9 i975 SHEEI 3 BF 3 IMPLEMENT HOLDER ANDMETHOD OF MAKING SAME The present application is a continuation in partof application, Ser. No. 128,878, filed Mar. 29, 1971 now abandoned.

The present invention relates to tool holders and, more particularly,the invention relates to a receptacle and carrier for tools, articlesand implements, and to a method for making such a receptacle andcarrier.

Artisans and craftsmen, such as draftsmen, mechanics, and repairmen,have a need to carry with them a number of tools, articles or implementsof their art or trade for use when they are away from their normal workplace. Many artisans and craftsmen prefer for this purpose a palletwhich has a plurality of implement receiving pockets and which isdimensioned to readily fit within a suitable carrying case. It is knownto provide a rigid backing board with a plurality of strips mounted uponthe rigid backing to define pockets for receiving the implements.Generally. the strips are pre-cut and then formed into desired shapes bylooping or folding them transversely to their longitudinal dimension.The strips are then riveted, sewed, glued or otherwise fastened to theboard in a plurality of corrugations so as to provide a series ofpockets, each having sufficient depth to receive an implement or tool.To form bottoms for the pockets, when desired, the longitudinal edges ofthe strips are folded inwardly and secured to the rigid backing.

In constructing such tool holders, a considerable amount of hand laboris required. i.e., an operator must cut the strips to the properdimensions, shape the strips to form pockets and then sew, rivet. glueor otherwise secure the individual strips to the rigid backing. Becauseof the extensive amount of hand labor required, the resulting toolholder is frequently misshapen and the pockets tend to separate from therigid backing. Moreover, to perform these operations entirely bymachinery is difficult because of the required shaping of the pieces toform the pockets.

Accordingly, a principal object of the invention is to provide animproved holder for tools, articles, and implements.

Another object of the invention is to provide an improved holder fortools, articles, or implements which is inexpensive and which is adaptedto rapid manufacture by machine.

Still another object of the invention is to provide an improved andrapid method for forming a holder for tools, articles, ad implements.

These and other objects of the invention will become more apparent fromthe following detailed description and accompanying drawings, in which:

FIG. 1 is a plan view of an implement holder showing various of thedetails thereof;

FIG. 2 is a cross-sectional view taken along the lines 2-2 in FIG. 1;

FIG. 3 is an enlarged and exploded view ofa section of FIG. I;

FIGS. 4 through 6 are sequential, diagramatic views ofa method offorming an implement holder of the type shown in FIG. 1;

FIGS. 7 through 8 are sequential, diagrammatic views of an alternativemethod of forming the implement holder;

FIG. 9 is a plan view of a further embodiment of an implement holder inaccordance with the invention, and

FIG. 10 is an enlarged view of a section of FIG. 9 showing furtherdetails.

Very generally, and with reference to FIG. 1 of the drawing, there isshown an implement holder 10 having a plurality of pockets for receivingand carrying a plurality of tools or other implements. The implementholder 10 can be employed as a pallet for maintaining the tools in aposition for immediate use adjacent the work place of the user. Theimplement holder I0 can be any desired shape but is preferablysubstantially rectangular in shape and preferably has dimensions thatare suitable to fit within a carrying case. The implement holder 10includes a wall 12 having at least one integral, permanently formed,outstanding cavity 14 and a backing 16 mounted in fact to face relationto the wall 12 and affixed to the wall by suitable means. As can be seenin FIG. 3, the backing 16 is joined in fact to face relation with thewall 12 so as to complete formation of pockets or loops 18 which areformed by the cavities l4 and the backing 16.

More particularly, there is illustrated in FIGS. 1 through 3 of thetbawings, the wall 12 in which cavities 14 are integrally formed. Thewall [2 is preferably fabricated from a thermoplastic or thermosettingplastic material which can be molded by heat or pressure to form thecavities 14. Typical materials which are useful for this purpose includevinyl resins, such as polyvinyl butyral and polyvinylchloride, styreneresins, such as polystyrene, amide resins, such as nylon, celluloseacetate, polyethylene and polypropylene. It should be understood,however, that any material which can be readily formed in a die bysuitable means can be used to fabricate the wall 12. In this connection,the material may be formed between a pair of dies by pressure alone orpressure in combination with heat. Some materials, such as thermoplasticmaterials, may be formed against a single die by vacuum thermoforming orpressure thermoforming. The material selected should be relativelyinexpensive and tear resistant. The material is prefera bly in sheetform and may be substantially rigid or may be flexible. Particularlypreferred are thermosetting plastic materials which may be formed byinjection molding.

It is a particular feature of the implement holder 10 that the cavities14 are integrally and permanently formed in the wall 12 and are notseparately looped or folded strips or cups which are formed and thensecured to the wall. This permits the cavities l4 and the wall 12 to beformed from a single sheet of material by a relatively simple mechanicaloperation. This permits saving of a considerable amount of hand laborheretofore necessary to fabricate separate materials and to secure themto the wall to provide pockets for an implement holder.

Preferably, a plurality of cavities I4 are formed in the wall I2 toaccommodate a number of implements, or articles, each cavity having thegeneral shape of the implement, or article. contemplated to be placed inthat cavity. In the implement holder 10 shown in FIG. I, a plurality ofpockets 14 of various sizes are formed in the wall 12. The pockets I4for receiving the implements are open at the top. The pockets can beeither open or closed on the bottom. It is a particular feature of theholder that both open end pockets and closed end pockets can beconcurrently formed by the method hereinafter described without anyadditional hand labor being required.

The backing 16 is mounted in face to face relation with the wall I2 inwhich the cavities I4 are formed to define a rear surface for eachpocketv The backing 16 provides additional support to the wall 12 andresults in an implement holder I which is substantially rigid. Thisenables the implement holder to be used as a pallet which convenientlycontains a plurality of imple ments or articles in a position where theyare readily available for use. The backing I6 is preferably fabricatedfrom a substantially non-flexible material, such as heavy cardboard,wood, or a plastic material, such as polystyrene. polypropylene or arigid vinyl resin sheet. It is apparent, however, that other rigidmaterials could also be employed for this purpose, such as a light gaugemetal sheet.

The wall 12 and the backing I6 are secured together in face to facerelationship to provide pockets 18 for receiving tools, articles orimplements. The wall and the backing can be fastened by any suitablemethod, such as sewing, glueing, heat sealing and riveting. In theillustrated embodiment of FIG. 1, a border 19 is positioned about theouter peripheries of both the wall 12 and the backing l6 and overlaps aportion of the front face of the wall and the rear face of the backing.The wall, the backing and the border are securely fastened by suitablefastening means, such as a row of stitches 20 extending through each ofthem. The row of stitches 20 is sufficient to secure the wall and thebacking together and provide the pockets I8. It is sometimes desirable,however, to provide additional fastening, such as by the rows ofstitches 21 about each group of pockets 18 to securely connect the wall12 and backing 16 in the vicinity of the pockets. This retards tearingof the material about the pockets when implements are inserted. Althoughit is generally unnecessary to provide rows of stitches between each ofthe pockets themselves, such stitches may be provided. especially whereheavy tools are contained in the pockets or where the pockets arerelatively large. Other fastening means, such as glueing, may be used toprovide complete bonding of the wall 12 to the backing 16 when desired.A decorative cover sheet (not shown) may be provided on the rear faceofthe backing 16, if desired, to conceal any stitching that is used.

The implement holder 10, as shown in FIGS. 1-3 of the drawings, may beconstructed by the method and apparatus shown in sequential views inFIGS. 46. For purposes of clarity, the apparatus shown in FIGS. 4-6provides an implement holder having only a single pocket. However, aplurality of cavities is generally formed in the wall. Generally, a wall12 is cut from a sheet of material. A cavity 14 is then molded therein.At least one end of the formed cavity is then opened. A backing I6 isthen attached to the sheet to provide the pocket.

More particularly, the wall 12 is positioned between a male die member22 and a corresponding female die member 23 (FIG. 4). Both the male andfemale die members are shaped to form a cavity of the desired dimensionsin the wall and at least one of the die members is heated by suitablemeans, such as the resistance coil 24. The die members are brought intoengagement, which forces the wall into the female die member 22 andthereby forms a cavity 14 in the wall. The cavity I4 is permanentlymolded in the wall by heat and pressure. The cavity may be provided withany desired configura tion to accomodate any shape of tool, article orimplement. As shown in FIG. 5 the cavity, as formed, includes a pair ofsubstantially parallel sides extending transversely to the plane of thewall 12, an outer surface located in a plane parallel to the wall andclosed top and bottom ends.

In FIG. 5, a sharp instrument, such as a knife 25, is illustrated ascutting an opening 26 in the cavity such that at least one end of theformed cavity is open. One or both of the top and bottom ends of thecavity are cut out and removed so that access to the interior of thecavity is achieved when the backing I6 fixed in place. The wall 12,having an open-ended cavity, is then secured to the backing 16 tocomplete the implement holder. As shown in FIG. 6, the wall 12 and thebacking 16 are secured together by a heat sealer 28 which includes aresistance heating coil 30. The heat produced by the coil 30 causes aphysical joining of the peripheral edges of the wall I2 and the backing16. It should be understood, however, that the wall 12 and the backing16 can be secured by any suitable means, such as glueing, stitching,riveting or other fastening methods.

In FIGS. 7-8, there is shown sequentially an alternative method offabricating the implement holder 10. In the alternative method a slit 32is first made in the sheet of material from which the wall 12 is cut.The slit 32 is formed by a sharp instrument, such as the knife 33 (FIG.7). The slit 32 is of suitable length such that when the cavity 14 ismolded in the wall 12, the slit is expanded to provide an open end 34 inthe cavity. It is apparent that if a pair of slits 32 are cut in thewall 12 at suitable positions, both slits will be expanded upon formingthe cavity so that the cavity has two open ends.

After the slit 32 is made in the sheet, the sheet is placed between themale and female die members described above. A guide 34 is used toposition the wall I2 so that the slit 32 is adjacent one of the endsurfaces of the male and female die members. As the die members areengaged, a cavity is permanently molded in the wall. Concurrently, theslit 32 is expanded by the die members to provide an open end 36 for thecavity which extends transversely to the plane of the flexible sheet.

The backing 16 is then secured to the wall 12 at least about theperiphery of the sheet, such as by heat sealing the peripheral edgesusing the heat sealer 28 (FIG. 6) or by stitching or other suitablemeans.

A particularly preferred embodiment of the present invention is shown inFIGS. 9 and 10. As shown in FIG. 9, a facing blank 4] is prepared byinjection molding. The facing blank is prepared from a thermosettingresin capable of being formed by injection molding. Particularlypreferred materials for preparing the facing blank 41 are polyvinylidenechloride, polyethylene, polypropylene, polyurethane, acrylonitrile,butadiene and styrene. The facing blank 41 is prepared in a one-stepoperation wherein a thermosetting resin is injection molded to provide asheet 43 with cavities 45 formed therein. The cavities 45 may be formedwith single or double openings as desired.

As further shown in FIG. 9, the facing blank 41 is formed with integral,multiple lugs 47. The lugs 47 are designed to mate with matching holesin backing material l6. The mating of the lugs 47 with the holes 49permits the backing I6 to be snapped into position in face to facerelationship with the facing blank 41. This permits rapid assembly ofthe implement holder. The lugs 47 may extend through the holes 49. Inthis case. the lugs may be cut off flush with the backing to provide asmooth surface. in a preferred embodiment of the present invention, theportion of the lugs extending beyond the backing are heated to deformthe lug and provide a seal, such as is formed by a metal rivet. Ofcourse, the facing blank 41 may be formed without the lugs 47 and thebacking 16 may be attached by other suitable means such as glueing,stitching or riveting. Facing blank 4] may also be formed with a flange5] around the perimeter of the facing blank. The flange 51 aids inalignment of the backing l6 and also provides a neatly finishedperimeter.

The present invention provides an improved implement holder forcontaining and carrying a number of tools or implements. An improved andrapid method of forming an implement holder which requires a minimum ofhand labor has been provided.

While one form of the invention has been shown and described, it shouldbe apparent that various modifications can be made therein withoutdeparting from the scope of the invention.

Various of the features of the invention are set forth in the followingclaims.

What is claimed is:

1. A holder for tools, articles or implements comprising a wall having aplurality of permanently formed cavities therein for receiving animplement, said cavities having at least one open end through which atool, article or implement may be inserted, and a backing, said wallhaving a plurality of lugs affixed to the surface of said wall, saidbacking having a plurality of holes formed therein, said holes being inmating relationship with said lugs. said backing being located inface-toface relationship with said wall with said lugs extending intosaid mating holes whereby said backing is secured to said wall so as toprovide, in combination with said wall, a plurality of pockets forreceiving tools, articles or implements.

2. An implement holder according to claim 1 wherein said wall is formedfrom thermoplastic or thermosetting plastic materials.

3. An implement holder according to claim 1 wherein said wall is formedfrom a plastic material selected from the group consisting of vinylresins, styrene resins. amide resins, cellulose acetate, polyethyleneand polypropylene.

4. An implement holder according to claim 1 wherein said backing is madefrom a material selected from the group consisting of cardboard, wood,metal sheet, or plastic.

5. An implement holder according to claim 1 wherein said cavity ismolded such that it has generally the shape of the tool, article orimplement which is to be received therein.

6. A method for making an implement holder for tools, articles orimplements comprising forming a sheet of material having a plurality ofcavities by injection molding, said cavities being formed by saidinjection molding in a manner such that at least one end of each cavityis open in a plane perpendicular to said sheet and said cavity is openin a plane parallel to said sheet, said sheet having integrally moldedtherein a plurity of lugs extending from said sheet on the side oppositesaid cavities, and securing a backing to said sheet in face-to-facerelation with said sheet to provide a plurality of open ended pocketsinto which tools, articles or implements may be inserted and retrieved.said backing having a plurality of holes which mate with said lugs tosecure said backing to said sheet.

7. A method according to claim 6 wherein said backing is secured to saidsheet by heat sealing said backing to said sheet at least about theperipheral edge thereof.

8. A method according to claim 6 further comprising providing a secondopening in at least one cavity of said sheet such that at least onepocket formed by securing said backing to said sheet is open at opposingends thereof.

9. A method in accordance with claim 6 wherein said injection moldedsheet has integral multiple lugs formed in the back side thereof andsaid backing has holes formed therein, said lugs and said holes being inaligned relationship whereby said backing may be joined to said sheet.

1. A holder for tools, articles or implements comprising a wall having aplurality of permanently formed cavities therein for receiving animplement, said cavities having at least one open end through which atool, article or implement may be inserted, and a backing, said wallhaving a plurality of lugs affixed to the surface of said wall, saidbacking having a plurality of holes formed therein, said holes being inmating relationship with said lugs, said backing being located inface-to-face relationship with said wall with said lugs extending intosaid mating holes whereby said backing is secured to said wall so as toprovide, in combination with said wall, a plurality of pockets forreceiving tools, articles or implements.
 2. An implement holderaccording to claim 1 wherein said wall is formed from thermoplastic orthermosetting plastic materials.
 3. An implement holder according toclaim 1 wherein said wall is formed from a plastic material selectedfrom the group consisting of vinyl resins, styrene resins, amide resins,cellulose acetate, polyethylene and polypropylene.
 4. An implementholder according to claim 1 wherein said backing is made from a materialselected from the group consisting of cardboard, wood, metal sheet, orplastic.
 5. An implement holder according to claim 1 wherein said cavityis molded such that it has generally the shape of the tool, article orimplement which is to be received therein.
 6. A method for making animplement holder for tools, articles or implements comprising forming asheet of material having a plurality of cavities by injection molding,said cavities being formed by said injection molding in a manner suchthat at least one end of each cavity is open in a plane perpendicular tosaid sheet and said cavity is open in a plane parallel to said sheet,said sheet having integrally molded therein a plurity of lugs extendingfrom said sheet on the side opposite said cavities, and securing abacking to said sheet in face-to-face relation with said sheet toprovide a plurality of open ended pockets into which tools, articles orimplements may be inserted and retrieved, said backing having aplurality of holes which mate with said lugs to secure said backing tosaid sheet.
 7. A method according to claim 6 wherein said backing issecured to said sheet by heat sealing said backing to said sheet atleast about the peripheral edge thereof.
 8. A method according to claim6 further comprising providing a second opening in at least one cavityof said sheet such that at least one pocket formed by securing saidbacking to said sheet is open at opposing ends thereof.
 9. A method inaccordance with claim 6 wherein said injection molded sheet has integralmultiple lugs formed in the back side thereof and said backing has holesformed therein, said lugs and said holes being in aligned relationshipwhereby said backing may be joined to said sheet.